TOX Joining Systems 80 201004 En

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TOX®-Joining-Systems

TOX®-Round JointTOX®-SKBTOX®-Flat JointTOX®-MICROpointTOX®-TWINpointTOX®-Vario JointTOX®-ClinchRivet

NEW

NEW

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The TOX®-Joining-SystemsThe best answer to every challenge.

Why a new technique?Because all previous methodshave involved economic and tech-nical problems. Take welding, forexample. A complex, expensiveprocess which can only beapplied to precoated sheet metalor aluminium with great difficulty.Surface coatings are damaged orsheet metals are not joined pro-perly. And there is still no reliableautomatic process control for allthese imponderable factors.

The TOX®-Joining technique putsan end to these problems. It joinsdifferent materials by means of adeep drawing-pressing process.And it does so without damage tothe surface, purely by displacingand forming.

Practice has alreadyshown the benefits ofTOX®, both technicallyand economically.

Side part of a seat

Sun roof frame

Hand brake lever

Engine mountEngine bonnet Brake disk covering

Home appliances: joining prepaintedsheet metal made possible with TOX®!

PC housings: TOX® preservesthe anticorrosive surface coating.

Kitchen drawer slides:with TOX®, ready for

installation.

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See for yourself:

+ TOX®-Round Joint: 30 to 60%cost savings as comparedto spot welding.

+ The TOX®-Joint achieves up to 70% of the static strength of a spot weld.

+ The dynamic strength of TOX®-Joint is higher than in spot welding.

+ The process can be automaticallymonitored and documented.

+ Simple, non-destructive quality control is possible.

+ The materials are strain hardenedat the connecting joint and aretherefore stronger compared tospot welding, which has significantstresses around the weld nugget,the TOX®-Joint does not exhibitany metallurgical residual effects.

+ Optimal corrosion resistance withgalvanized and prepaintedmaterials, since the protectivelayer flows with the material.

+ Perfect joints are producedeven with narrow flanges andsmall mounting spaces.

+ Outstanding conductivity forelectric components.

+ Cold forming process is ideal for hybrid connections (gluing and clinching).

+ The TOX®-Round Joint can carryshear and pull stress loads, in-dependent of the load orientation.

Convincing features:

+ The TOX®-MICROpoint isespecially applicable for verythin metal sheets.

+ The TOX®-TWINpoint:a non-rotating TOX®-Point forsmall flange widths.

+ TOX®-ClinchRivet:Comparable strength to self-piercing rivets but without cutting the sheet metal layers.

Dr. Rudolf Eberle innovation prizefor exemplary achievement.

Seat rail

Window lifter

TOX® advantages for a good connection

For each operation a suitablesolution:

• Point diameter from 1,5 to 26 mm

• Individual sheet thicknessesfrom 0,1 to 11 mm

• 2 – 4 sheet metal layers

• Composite layers(steel/glue/aluminium)

• Extensive know-how

• World-wide service

How may we help you?

With our TOX® testreport we guaranteeour technology.

Zinc coated parts:with TOX®, the coa-ting remains intact!

Gas meter housing: TOX® joints are leakproof. Miniature relay contacts:

securely joined withTOX®-MICROpointØ 2 mm.

4

2

. . . . . . . . . . . .

Einzelblechdicke ts = tm (mm)

Fs

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k(N

)

2

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. ,2

. ,

2

. ,

. ,2

. ,

2

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X-M

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TOX®-TechnologyClinching facts

Durability of TOX®

Static strength up to 70% of a spotweld, with positive strain hardening,without damage to the surface coat-ing, and typically more economical.Isn’t all this worth looking at?

The strength behind the TOX®-JointIn the TOX®-Round Joint process,the material strain hardening in theneck area and the lacking of anynotch effects produce the highretaining forces. This is the directresult of the fixed, rigid die. For thisreason, even the TOX®-SKB die hasfixed segments.

The TOX®-ClinchRivet process com-bines the advantages of the RoundJoint with those of a rivetingprocess.

The dynamic strength is higherthan in spot welding.Advantageous dynamic strengthwithout notch effect in the joint - thismeans: the life of the TOX®-RoundJoint lasts much longer than that ofa weld point.

On the right:The TOX®-Joint in customer testResults of endurance tests for sam-ples with TOX®-Round Joints andspot welds.The joints were exposed to an initialload of 1 kN and a frequency ofapproximately 35 Hz. The fatigue lifeof the joint was measured until fail-ure.

Test series standard tool set(without tool change)

Fs, Fk (N) X-Dimension (mm)

Surface: as-rolled tp= punch sideMaterial: St 1203 (CRS) td= die side

2,25

2

1,75

1,5

1,25

1

0,75

0,5

0,25

0

4500

4000

3500

3000

2500

2000

1500

1000

500

0

This is how a TOX®-Joint isformed

• Penetration• Interlock formation of punch

side sheet metal• Completed TOX®-Joint

For

ce a

pmlit

ude

Fa

2000

1500

1000

500

Joined samples, vapour degreasedFD,100%

280 N Spot welding

Clinching, star shape

FD = fatigue strength

TOX®-Round Joint

250 N

560 N

103 104 105 106 107 108

Number of cycles N

20s

F

Source: EFB (German Research Group) research report No. 37

St 1403/s= 0.8 mm

1 2 3 4

9

8

7

6

5

4

3

2

1

0

with ageing1000-hr-salt spray test1000-hr-climate test

1.00 1.25 1.55 1.75 2.15 2.55

Fatigue strength under themost adverse conditions.Corrosion tests have shown thatbecause the surface coating is notdamaged during the round jointprocess, the anti-corrosive propertiesof the joined sheet metals, e.g., alu-minized or galvanized, are main-tained. The TOX®-Joining-Systemdoes not cut the surface of the mate-rials to be joined, as the coating flowswith the material and remains intact.

Corrosion testShear forceFs in kN

TOX®-Round Joint 6 mm

TOX®-ClinchRivetTOX®-Round Joint

1 = material = St 1403 (crs)Individual sheet thicknesst = 0.8 mmvapour degreased

2 = material = St 1403 (crs)t = 0.8 mm adhesive film

3 = material = St 1403 (crs)t = 0.8 mm edge-formedseam adhesive paste

4 = material = Al Mg 5 Mnvapour degreased

Cross tension Fk

Dimension X

Shear tension Fs

Single sheet metal thicknesstp = td (mm) ts = tm (mm)

5

2800

2600

2400

2200

2000

1800

1600

1400

1200

1000

450

400

350

300

250

200

150

100

50

0

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160.000

140.000

120.000

100.000

80.000

60.000

40.000

20.000

0

t = < 1,0 t = 1,0 – 1,2 t = 1,3 – 1,5 t = 1,6 – 2,0

normaler Standmengenbereich

Einzelblechdicken (mm)

Anz

ahl F

ügep

unkt

e / S

atz

Werkzeugstandmengen bei EdelstahlBlechwerkstoff: 1.4301 ölig / TOX®-Punkt 8,0 mm

TOX®-TechnologyThe advantage for you and the environment:cost effective and efficient

TOX®-Joining: the simple processcuts your manufacturing costs.

The system efficiency and the ser-vice life of the tools are closely inter-dependent.

(1) shows a cost comparison for thesingle joint technique between spotwelding and TOX®-Joining for a mildsteel application. The TOX®-Joining-System can be used in multipointapplications, which can increaseconsiderably the cost differencebetween TOX®-Joining and spotwelding.

(2) shows the normal service life ofTOX® tools. The given values andguidelines depend on the particularapplication.

TOX®-ClinchRivetThe TOX®-ClinchRivet is a logicalfurther development of the TOX®-Round Joint with greater resistancefor crash applications. By filling thejoint with the rivet, the TOX®-ClinchRivet process increases thejoint strength considerably, especial-ly the shear strength. Higherstrength can be achieved whencompared to pierce rivets, especiallywith thin sheet metals. It is importantto mention that with TOX®-ClinchRiv-eting, the upper sheet metal layerwill not be cut: no risk of corrosion.

See data sheet 80.04 for additionalinformation.

TOX®-Joining of Stainless SteelStainless steel presents specialrequirements for forming processes.The required higher forming forcesresult in higher surface stresses onthe joining tools. The TOX®-JoiningTechnology can be used safely andefficiently even for stainless steelapplications. Continuous tool devel-opment and experience with manyapplications have resulted in hightool life.

t = < 1,0 t = 1,0 – 1,2 t = 1,3 – 1,5 t = 1,6 – 2,0

normal tool life range

Individual sheet metal thickness [mm]

160.000

140.000

120.000

100.000

80.000

60.000

40.000

20.000

0Num

ber

of jo

ints

bef

ore

tool

cha

nge

Tool life with stainless steelSheet metal material: stainless steel 1,4301 (A/SI 304) oily / TOX®-Point 8,0 mm

Material

500 000

400 000

300 000

200 000

100 000

Steel

normal tool life range

(2) Number of TOX®-Jointsuntil tool change

AluminiumSteelgalvanizedprepainted

Customers have alreadyachieved much higher tool life.

Mean value Fs in NMean value Fk in NTensile strength Shear strength

Retainingforce in N

Type of Joint

Comparison of Joint Strength for Various Joining at AC120 1,25 mm into 1,25 mm

TOX®-ClinchRivet Pierce rivet X Pierce rivet Y

Cos

t pe

r 10

0.00

0 jo

ints

in E

uro

Tooling Operating costs Investment

TOX®-Joining Spot welding

(1) Cost per joining


The TOX®-Joining-Systems:Simplicity is our strength.

The patented TOX®-Round Joint is the core of our techno-logy. A simple round punch presses the materials to be joi-ned into the die cavity. As the force continues to increase,the punch side material is forced to spread outwards withinthe die side material. The result: an aesthetically pleasinground button, which joins clearly without any burrs or sharpedges on which corrosion could set in. Even with aluminizedor galvanized sheet metals, the anti-corrosive propertiesremain intact as the protective layer flows with the material.Find additional information in the data sheet 80.100.

TOX®-Round Joint

The TOX®-Round Joint:Smart Joining Technology withno added fasteners.Strength:The materials are plasticallydeformed in the joining area, there-fore, increasing the strength. Thereare no stress concentration factors.The advantages of the TOX®-Join-ing-System can also be appreciatedin regards to the environment -particularly in comparison to weld-ing. Just think of welding alumini-um, galvanized or prepainted sheetmetal!Cutting costs with TOX®

Besides the directly measurablecost advantages, considerablesavings can also be made with amuch simpler production sequence.For example, it is often possible topunch, bend and join in one pro-gressive die. This saves an entireworking cycle as well as transporta-tion to the joining station - or weld-ing shop. Which is a great advan-tage in terms of logistics.

Process sequence

This TOX® double point with almost double the strength ofa single point prevents rotation of the two layers againsteach other. The TOX®-TWINpoint is ideal for narrow flangesdue to its compact design. This point also features a soliddie with the same simple process and the advantages ofthe TOX®-Round Joint.

The miniature TOX®-Round Joint with point diameters of1.5 to 2 mm is the answer to the miniaturization of compo-nents. It is ideal for sheet metal thicknesses from 0.1 –0.5 mm and narrow flanges. The electrical conductivity bet-ween the joined layers is comparable to other connections.

TOX®-TWINpoint

TOX®-MICROpoint


In some instances, the button formed by the TOX®-Point may be undesirable.That’s why we developed theTOX®-Flat Joint.

TOX® Flat Joint / TOX®-SKB Flat

Forming the TOX®-Flat Joint:• the first step is to produce the

standard TOX®-Round Joint orTOX®-SKB Joint

• The resulting button is flattenedin a secondary operation.

The high shear and pull strengthsof the TOX®-Point are left virtuallyintact.

Process sequence

A special clinch-die has solid and flexible segments.The materials and the punch are centered by the fixedsegments, thereby guaranteeing that the joint formationis perfectly concentric. The mobile elements between thesolid segments allow an interlocking of the material in thejoint.

TOX®-SKB

The advantages are seen in amore flat protrusion of the jointand a higher flexibility when sheetmetals of different thickness haveto be joined with one tool set.

The special arrangement of thesprings allows extremely slendertools and thus better accessibilityand minimal interference com-pared with conventional die con-struction without solid part.

The SKB die shows its strengthspecially when glue is usedbetween the sheet metal layers.Furthermore, it has been success-fully implemented for the TOX®-ClinchRivet (see page 8).

Process sequence


Specialities of the procedure

Process sequence

The TOX®-Point for difficult cases: joining of sheet metalwith large differences in thickness, joining of high strength ornon ductile materials with ductile materials or joining of nonmetallic materials.Characteristics: one layer is pre-punched, the ductilematerial is then pushed through the hole. The connectionhas radial and axial strength. Multiple joints can be appliedin a single press stroke. This process requires precisealignment of the parts.

TOX®-Vario Joint I TOX®-Vario Joint II

In the case of the patented TOX®-ClinchRivet, the actualrivet joining is made from a simple cylinder rivet in a joiningprocess using drawing/pressing methods. Similar to theTOX®-Round Joint, the material to be joined is not cut butled through the die form thus producing a very resistantjoint - also in the case of thin materials.

Multijoint applications increase cost advantages.Find additional information in the corresponding data sheet.

TOX®-ClinchRivet

The special advantage of the TOX®-ClinchRivet is the simple, symme-trical and inexpensive rivet. Thisresults in the troublefree feed andcompression. The materials to bejoined gain an additional retainingcomponent. A clean and highlyreproducible joint is created.

All technological characteristicsand quality criteria of the TOX®-Round Joint also apply to theTOX®-ClinchRivet.

Process sequence


TOX® Standards:The modular program - flexible and field-proven

TOX® Tools

TOX® flat plate dieoffers unbeatable accessin hard to reach corners.

TOX® Tool Holderwith integrated stripper

TOX®-Robot- and Machine tongswith pneumo-hydraulic, electric-or hydraulic drive.

TOX®-Production MachineTOX®-Presses with integratedmulitpoint die sets.Our know-how, your advantage.

TOX® Die Setsthe most economical way to useTOX®. Multiple points can beproduced in one operation.

TOX®-PowerKurverfor simultaneousclamping and joining. No need for repeated clamping andfixturing. Optimal accessibility for largepanels due to > 90° operating angle.With pneumatic or electric drive.

TOX®-Handtongsthe suspensionoffers an optimumhandling.

TOX®-Tongs Fixturesin single and multipoint design,specially adapted to your component.They are pneumatic, pneumatic-hydraulic or hydraulic driven.

TOX®-ClinchRivetstandardized swage heads includingfeed and fill level control for installa-tion in single and multijoint applicati-ons. Appropriate for robots.

TOX®-FinePressHigh-quality benchtop presses –compact and perfect.

10

KN

30

25

20

15

10

5

07 6 5 4 3 2 1 0

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The specially adapted process moni-toring system for the TOX®-Joiningtechnique helps you to check thecompetitive factor of quality:• for each produced component• for each clinch point in the

component

A cost effective production monito-ring for short cycle times requires acontrol system which is integrated intothe line - in short, a system like theTOX® process monitoring system.

The TOX® process monitoring systemguarantees your quality standards,not only for mass production, butalso for small-scale manufacturing.

TOX® process monitoring keeps a constant check on your clinch points.

Functional principle:Force sensors measure the press for-ce at the clinch points. A position indi-cator monitors the attainment of con-trol dimension “X” (quality dimension).Once the position indicator signalsthat control dimension “X” has

been reached, the press forces mea-sured by the load cells are comparedwith the nominal press forces. TheTOX® point is satisfactory if the mea-sured press force lies within the pre-set tolerance range. Thus, it is possi-ble to make an assessment on mate-

rial type, strength and thickness, righttool combination as well as tool failureor missing layer of sheet metal.As alternative it is possible to evalua-te the complete Force-Travel charac-teristic curve (EPW 400 measuringprinciple).

Resistance to pull and shear loads isdependent on the control dimension“X”, provided that the joining parame-ters and the service life of the toolshave been observed.

Evaluation Units for Monitoring of Clinch Processes

- Force monitoring of clinching processes

- Trend monitoring- Process sequencing- Network capability over Ethernet

TCP/IP- Expandable to userdefined

processes- With and without display

TOX® process monitoring CEP 400

TOX®-ToolCheck pneumatic testing of clinching dies

The evaluation device can be selec-ted according to each requirement.From 1- to 16-channel clinch monito-ring all the way to continuous measu-ring in force-travel-pressing monito-ring.

Various evaluation methods allow fordifferent analysis of your processes.Diverse communication interfacesallow for simple and quick data trans-fer to the data storage.

X-Dimension (mm)

Punch

Compres-sed Air

Stripper

Die

TOX®softWare

EthernetInterbus/ServiceNet/Profibus

RS 232/485PLC

See “TOX®-Controls”

catalog for detailed

informationTOX®-ControlsandTOX®-Monitoring

NETWORK

The die monitoring system TOX®-ToolCheck, together with the processmonitoring, checks the condition ofthe TOX® clinching dies. This ensuresthat the joining process is always per-formed with an intact die. Any poten-tial defects, like missing or (e.g. bycontamination) jammed moving ele-ments of the SKB die, as well asruptures on either the solid TOX® die

or on the fixed segments of SKB, areidentified within < 1 second.

+ Optimum tool life quantity+ Increase production reliability+ Maximum tool life usage

For detailed information, see TOX®

Data Sheet 80.06.


The dimension “X” defines the joint quality!

Now it’s possible to precisely controlthe dimension “X”, the remaining bottomthickness of the joint after the clinchingprocess, by simultaneously compensatingfor the deflection of the press unit.

Controlled Precision Clinchingusing Electric Servo Drives

Typical Application:TOX®-Clinch Robot-Tongs with a compact electromechanical ser-vo drive EPMK and controller including the free TOX®softWare.

Process monitoring using envelope curves

+ Full monitoring within the set point and target windows, i.e. the force/travel characteristics curve can not fall outside theupper and lower limits

+ Decide for yourself!For curves deviating from the envelope, these options apply:

process will continue until target window is reachedstop process

+ TOX®softWareIncluded with delivery: This software, specially developed by TOX® PRESSOTECHNIK, integrates all appropriately equipped TOX® products. Programming, visualization and displaying, networking and archiving, all this can be done using a common platform.

set point

envelope

target window

TOX®softWare = User friendly

+ Automated learning of the processes and the forcelimits in the target window, as well as for the envelope.

+ No programming, only parameterizing

+ automatic scaling of the envelope display

+ simple, user friendly user platform

The dimension “X” is determined in the TOX® test labs.

Now: + active stabilization of variancestechnical optimum achieved with an accuracy of ± 0,04 mm

+ Flexibility, precision, minimum setup times

+ the dimension “X” is assured independent ofmaterial combination and properties

Point diameter

Controldimension "X"Controldimension "X"

ePunch sideDie side

Picture 1: this easy!Input of parameters for the clinch process is donedirectly on the screen.

Picture 2 shows examples of available operatingcommands.

Picture 2

Picture 1

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Our Worldwide Sales and Service Network

80.201004.en Subject to technical alterations.

TOX®-Production

Systems

TOX®-Press-Fitting

TOX®-Punching

TOX®-Coining

TOX®-Tongs

TOX®-Joining-

Systems

TOX®-Controls,

TOX®-Monitoring

TOX®-Presses

TOX®-FinePress

TOX®-ElectricDrive

TOX®-PowerKurver

TOX®-Powerpackage

Product Range

TOX® PRESSOTECHNIKRiedstrasse 4D-88250 WeingartenTel. +49 (0) 7 51 / 50 07-0Fax +49 (0) 7 51 / 5 23 91E-Mail: [email protected]

GMBH &CO. KG

TOX Joining Systems 80 201004 En

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